Manuals

The machine installation can be done in differently desired directions, for this purpose an iron or sound wood Mounting Platform must be prepared and fixed firmly to the hull at the required height and perfectly square with the rudder stock.

A : Fastening of the iron base:

Before drilling the mounting platform, with the base ( already drilled), make sure that:

1) The rudder is in a symmetrical position with the boat

2) The cylinder rod is in the intermediate position of its course (1/2 way)

3) The base axis in parallel with the boat axis

4) The base is at the correct distance from the rudder axis “Steering gear axis centre” to be respected after which it may be drilled and tightened with bolts.

B : Alignment between rudder axis and cylinder axis:

Before tightening the bolts, suitable thicknesses of packing should be used, (if the mounting platform could not be planed before ) in a way that the inclination between the cylinder axis and the two gudgeon pins (tiller arm base), is not above 2°; errors within this range are compensated for by the ball joints on the cylinder rods.

A good alignment is to be preferred as well as the welded stops at the base angles, after tightening the bolts.

TUBING: Rigid tubing:

It is advisable to use steel tubing without welding (Mannesmann) of different diameters as indicated in the drawing “Hydraulic Scheme”

The various connections must be made with steel flanges to be welded electrically to the tube, or threaded steel pipe fittings or welded steel pipe fittings; do not use hemp on the threaded pipe fittings but an appropriate Teflon tape, found on sale.

Check to see that the tubes are internally clean before assembling, fasten well with brackets so that they will not vibrate and do not pass inside the cold stores, even if the oil used is at a low freezing point.

The position of the tube connections “1” and “2” which go from the hydraulic transmitter to the device and then to the actuator must not be inverted.

Flexible tubing:

The flexible tubing should be mounted with the external fitting, using two spanners so no deformation occurs.

They should be free of any contact, so no rubbing occurs during working.

FILLING THE PLANT:

Unscrew one of the air bleeder screws on the cylinder and insert a transparent plastic tubing on it and place the other end into a bucket.

Now start filling the Transmitter with oil and slowly turn the hydraulic transmitter steering wheel in the same direction as the unscrewed air bleeder screw until clean oil comes out of the tube with no air bubbles. Close the air bleeder screw.

Now repeat the same operation with the other air bleeder screw on the cylinder, filling and turning the wheel in the opposite direction until clean oil comes out of the tube with no air bubbles.

The oil level in the transmitter should not be above the piston block inside.

Once finished filling the system, turn the wheel from hard over to hard over several times to see if the rudder responds correctly and check that there are no leaks at the connections. The transmitter plug/cap must be vented.

EMERGENCY:

In case of an emergency, open the By-pass valve and manoeuvre with the Emergency Tiller armi.

MAINTENANCE:

It is sufficient for the maintenance to periodically control the transmitter oil level, which should not be below the minimum level.
Periodically grease the device and the stainless steel piston rods.
The piston rods should be protected from eventual leaking from the top cover

The machine installation can be done in differently desired directions, for this purpose an iron or
sound wood Mounting Platform must be prepared and fixed firmly to the hull at the required
height and perfectly square with the rudder stock.

A : Fastening of the iron base:

Before drilling the mounting platform, with the base (already drilled), make sure that:

1) The rudder is in a symmetrical position with the boat

2) The cylinder rod is in the intermediate position of its course (1/2 way)

3) The support base axis in parallel with the boat axis

4) The support base is at the correct distance from the rudder centre; “Distance between Centres” to be respected after which the mounting platform may be drilled and the support base tightened with bolts

B : Alignment between rudder axis and cylinder axis:

Before tightening the bolts, suitable thicknesses of packing should be used, (if the mounting platform could not be planed before ) in a way that the inclination between the cylinder axis and the two gudgeon pins (tiller arm base), is not above 2°; errors within this range are compensated for by the ball joints on the cylinder rods.

A good alignment is to be preferred as well as the welded stops at the base angles, after tightening the bolts.

TUBING:

Rigid tubing:

It is advisable to use steel tubing without welding (Mannesman) of different diameters as indicated in the drawing “Hydraulic Scheme”.

The various connections must be made with steel flanges to be welded electrically to the tube, or
threaded steel pipe fittings or welded steel pipe fittings; do not use hemp on the threaded pipe
fittings but an appropriate Teflon tape, found on sale.

Check to see that the tubes are internally clean before assembling, fasten well with brackets so that they will not vibrate and do not pass inside the cold stores, even if the oil used is at a low freezing point.

The position of the tube connections “1” and “2” which go from the hydraulic transmitter to the
device and then to the actuator must not be inverted.

Flexible tubing:

The flexible tubing should be mounted with the external fitting, using two spanners so no deformation occurs

They should be free of any contact, so no rubbing occurs during working.

GENERAL DESCRIPTION

Hydraulic transmitter:

The transmitter consists of an axial piston pump, mounted on a pedestal or directly on the consolle
using an anodized aluminium plate; manually operated by a wooden steering wheel, which sends
oil to the actuator

Electric joystick:

The “fixed” type of joystick, consists of a water-tight aluminium box in which are mounted two
micro switches, these work by a spring lever which returns to the centre.

The “portable” type of joystick, consists of a water-tight aluminium casting with handle where the
red and green operating buttons are installed

Pumping set:

It provides the actuator with the hydraulic power necessary to steer the rudder within the conditions and time regulated by RINA or as agreed upon at time of order. The execution of the pumping sets are as follows:

“W” transmission from onboard motor;

“X” transmission with indipendant electric motor;

“Y” transmission with compact electric motor.

The “Y”

version represents the standard version, the tank acts as a base for the electric motor and is complete with filters, control and safety valves; the rudder control is obtained by an a electro-valve controlled by the electric joystick on the bridge.

Actuator: Steering gear type CL……..

One power cylinder with double effect and identical chambers mounted on one frame or base connect with a clevis to the tiller arm keyed on the rudder shaft.

A by-pass exclusion interception valve is supplied.

CONTROL SYSTEMS

Manual hydraulic system “A”:

By turning the steering wheel the hydraulic pump/transmitter sends oil to the actuator/cylinder which moves the tiller arm, and thus the rudder shaft in the desired direction.

The power sent to the actuator is supplied by the operator and depends upon the diameter of the wheel, the ratio between the delivery of the hydraulic transmitter and c.c. of the actuator (the number of turns is decided on by this ratio), as well as the tube dimensions for reasons of friction.

NON PROPORTIONAL Electric system:

The electric joystick on the bridge, commands the opening of the pumping set control valve, oil is pressurized by the hydraulic pump of the pumping set, and moves the rudder actuator/cylinder until the lever or button of the electric tiller/joystick is left, in this case energy is required by the electric motor;

but the control of the angular movement of the rudder happens by means of a rudder angle indicator.

EMERGENCY:

In case of an electric power failure the manouvre is always possible with the hydraulic transmitter.

In case of the manual hydraulic system “A” failure proceed by opening the actuator/cylinder by-pass, and manouvre with the emergency tiller arm.

FILLING THE PLANT

1 Fill the pumping set tank, start the electric motor and check that it turns in the same direction as the hydraulic pump, if not stop the motor immediately and invert the elecctri cables.

2 Open the actuator/ cylinder by-pass valve, start the electric motor and electro-valve with the push button, it doesn’t matter which of the two, but it’s important to verify the direction;close the interception valve cocks mounted at the tube junctions (right and left) of the plant;check that the tank is full and close with a breather-less screw cap.

3 If provided, fill the compensation tank and its tubing until all the air has risen out the tank.

Check that no air remains in the hydraulic pump/ transmitter, by unscrewing the filler cap and seeing if oil comes out, close with breather-less screw cap.

If no compensation tank is provided with the plant, it means that the transmitter/pump acts as a tank (in case of a double command station, the control must be done before on the first station which is the lowest with breather-less cap, and the second station which is higher must be filled).

4 The filling of the main tubing, must be done in the following way:

* Take off the hydraulic pump/transmitter tubing (always the highest if a double station) insert a small plastic hose onto the pump connection and place the other end in a bucket,

* Close with a cap the unsrewed hydraulic pump/ transmitter tubing,

* Fill the hydraulic pump/transmitter or compensation tank with oil and turn the steering wheel in the same direction as the other tubing connected to the pump.

* Continue turning and filling with oil until all the air is bled from the system by checking the hose in the bucket,

* Check that the oil comes out clean and without air bubbles, stop turning the wheel and stop filling with oil, now reconnect the tubing to the pump

NB: The recuperated oil in the bucket may be reused, but must be left to decant for the elimination of dirt and oil emulsion obtained during its movement in the tubing.

5 Move to the rudder actuator/cylinder:

* Take off the air-bleeder screw and wait until oil comes out, check and fill the hydraulic pump/ transmitter or compensation tank;

* Close the air bleeder screw and the by-pass valve opened at point 2 and reopen the interception valve cocks of pumping set closed at point 2 of this filling procedure.

TESTING THE PLANT

Check list:

* By-pass: closed

* Interception tubing of pumping set: open

* Interception tubing of compensation: open

* Air bleeder screw actuator/cylinder: closed

* Oil level: O.K.

* Breather cap: on highest station or compensation tank.

At this point, test the manoeuvre by turning the wheel from side to side counting the number of turns that should result from the ratio between the hydraulic transmitter/helm pump displacement and actuator/cylinder displacement.Start the pumping set and test the electric tiller/transmitter and autopilot if supplied.

OIL TO BE USED:

It is advisable to use an hydraulic oil with the following characteristics:

4 Slowly turn the servo unit wheel for some turns of steering wheel. If there are more than one command station, turn one at a time.

5 Close the by-pass valve cock

6 Unscrew, one at a time, the breather plugs situated on top of the cylinder, continually turning slowly the servo unit wheel, firstly in one direction, then the other, to eliminate the air from the cylinder

7 When oil comes out whitout air bubbles, screw in the breather plugs.

The machine installation can be done in differently desired directions, for this purpose an iron or a solid wooden Mounting Platform must be prepared and fixed firmly to the hull at the required height and perfectly square with the rudder stock.

A : Fastening of the iron base:

Before drilling the mounting platform, with the base ( already drilled), make sure that:

1) The rudder is in a symmetrical position with the boat

2) The cylinder rod is in the intermediate position of its course (1/2 way)

3) The support base axis in parallel with the boat axis

4) The support base is at the correct distance from the rudder centre; “Distance between Centres” to be respected after which the mounting platform may be drilled and the support base tightened with bolts.

B : Alignment between rudder axis and cylinder axis:

Before tightening the bolts, suitable thicknesses of packing should be used, (if the mounting platform could not be planed before ) in a way that the inclination between the cylinder axis and the two gudgeon pins (tiller arm base), is not above 2°; errors within this range are compensated for by the ball joints on the cylinder rods.

A good alignment is to be preferred as well as the welded stops at the base angles, after tightening the bolts.

TUBING:

Rigid tubing:

It is advisable to use steel tubing without welding (Mannesman) of different diameters as indicated in the drawing “Hydraulic Scheme”.

The various connections must be made with steel flanges to be welded electrically to the tube, or threaded steel pipe fittings or welded steel pipe fittings; do not use hemp on the threaded pipe fittings but an appropriate Teflon tape, found on sale.

Check to see that the tubes are internally clean before assembling, fasten well with brackets so that they will not vibrate and do not pass inside the cold stores, even if the oil used is at a low freezing point.

The position of the tube connections “1” and “2” which go from the hydraulic transmitter to the device and then to the actuator must not be inverted.

Flexible tubing:

The flexible tubing should be mounted with the external fitting, using two spanners so no deformation occurs.

They should be free of any contact, so no rubbing occurs during working.

ENERAL DESCRIPTION

Hydraulic transmitter:

The transmitter consists of an axial piston pump, mounted on a pedestal or directly on the consol using an anodized aluminium plate; manually operated by a wooden steering wheel, which sends oil to the actuator.

Electric transmitter:

The “fixed” type of transmitter, consists of a water-tight aluminium box in which are mounted two micro switches, these work by a spring lever which returns to the centre..

The “portable” type of transmitter, consists of a water-tight aluminium casting with handle where the red and green operating buttons are installed.

Power Pack:

It provides the actuator with the hydraulic power necessary to steer the rudder within the conditions and time regulated by RINA or as agreed upon at time of order.
The execution of the pumping sets are as follows:

“W” transmission from onboard motor;

“X” transmission with independant electric motor;

“Y” transmission with compact electric motor.

The “Y” version represents the standard version, the tank acts as a base for the electric motor and is complete with filters, control and safety valves; the rudder control is obtained by an a solenoid valve controlled by the electric transmitter on the bridge.

Actuator: Steering gear type CL……..

One power cylinder with double effect and identical chambers mounted on one frame or base connected with a clevis to the tiller arm keyed on to the rudder shaft.

A by-pass exclusion interception valve is supplied.

COMMAND SYSTEM

Manual hydraulic system “A”:

By turning the steering wheel the hydraulic pump/transmitter sends oil to the actuator/cylinder which moves the tiller arm, and thus the rudder shaft in the desired direction.
The power sent to the actuator is supplied by the operator and is amplified depending upon the ratio between the delivery per turn of the hydraulic transmitter and the displacement of the actuator (the number of turns is decided on by this ratio),and the diameter of the wheel as well as the tube dimensions for reasons of friction.

Hydraulic Servo-Assisted System (F.U.) :

By starting the pumping unit, piloting pressure is generated at the double selector valve that moves into work position, this puts into communication the hydraulic transmitter with the servo valve piloting chamber and feed-back cylinder; by turning the steering wheel the command of the servo-valve cursor is obtained that drives the power cylinder; thus obtaining the opening of the servo-valve according to the speed of rotation of the steering wheel.

With this system you can obtain a given angular movement of the rudder with a certain number of turns of the steering wheel.

In case of damage to the feedback cylinder, it can be excluded by opening the manual by-pass valve and manoeuvre with the (N.F.U.) system.

The changeover from the F.U. control system to the manual system, is done automatically by switching off the pumping units.

Electric Servo-Assisted System (N.F.U.):

The control device includes two solenoids (one for power cylinder and one for the feed-back by-pass ) electrically connected in parallel via a low voltage electric circuit; the Tiller (Joystick) and / or Autopilot are on the same circuit , these simultaneously drive the solenoid valve that feeds the power cylinders, and the by-pass valve solenoid of the feedback cylinder.

NB. In case of a total electrical blackout the change-over to manual operation takes place automatically without any manual operation in the hydraulic system, the manoeuvre can continue from the bridge but with an increase of the number of turns from hardover to hardover.

With Emergency Manual Tiller:

If provided, install the pulley block and fit the emergency manual tiller; from the by-pass valve the tubes are excluded and the power cylinder chambers are put into communication; the manoeuvre is possible with the pulley block by following the orders from the bridge.

AUTOMATIC FILLING OF SYSTEM:

After filling the power pack tank, switch on the electric motor, the compensation line “C” automatically fills the hydraulic transmitter.

Unscrew one of the air bleeder screws on the feedback cylinder and insert a transparent plastic tubing, with the other end into the tank; slowly turn the hydraulic transmitter steering wheel in the same direction as the removed air bleeder screw until clean oil comes out of the tube with no air bubbles.

Close the air bleeder screw, and repeat the same operation with the other air bleeder screw, turning the wheel in the opposite direction.
Now the command circuit is filled (feedback system line).

To fill the tubing line of the main cylinder, unplug the electrical connections on the selector Pos.9 Dwg. 3849 Rev.1and the bypass valve Pos.6 Dwg. 3849 Rev.1. Unscrew the air bleeder screw, on the main cylinder, and insert a transparent plastic tubing for the recovery of oil, and slowly turn the wheel in same the direction of the open bleeder screw until the total elimination of air from the cylinder and tubing. Repeat the same procedure on the other side.

It is a good idea to proceed with both pumps to eliminate the air in all branches of the tubing.

At this point all relevant tests can be effected by starting to check the oil level in the service tank, test with the pumping unit in operation, manoeuvre with the transmitter, and the electric Tiller if provided.

NB: The direction of manouevre, obtained by the hydraulic manual system, and the pumping unit switched off, is authentic and should correspond to the direction of manoeuvring the vessel, otherwise the connection of the main tubing to the interception valve must be reversed.

For system (FU) with the pumping unit switched on, the manouevre direction of the hydraulic transmitter , must correspond to that of the hydraulic manual manouevre, otherwise the tubing of the feedback cylinder must be reversed.

For the electric (NFU) it is sufficient to exchange the connectors on the solenoid valve control.

SYSTEM TEST

To sum up:

* By-pass: closed

* Tubing interception of pumping unit: open

* Tubing interception of compensation: open

* Bleeder screws actuator/cylinder : closed

* Oil level: okay

* Vented plug: on highest station or compensation tank if installed.

You may now test manoeuvre with the wheel, going from hard over to hard over by counting the number of turns that should result by dividing the actuator /cylinder displacement with the hydraulic transmitter / pump displacement,

Start the pumping unit and test the electric tiller/joystick and autopilot if provided.

OIL TO BE USED:

It is advisable to use an hydraulic oil the following characteristics:

The Marsili company can also supply complete control systems for vessels from 5m up to 90m and particularly for tugboats, pusher crafts, transport fleeting, fishing boats, motor yacht, sailing vessels, navy, patrol vessels, etc.